Electrical tape and plug connector

ABSTRACT

An electrical tape and plug connector to facilitate simplified installation of electrical wiring. Substantially flat or film conductors are sandwiched between insulating layers of protective material. The sandwich includes a ground conductor insulated from the two main current carrying conductors. One surface of side of the tape or cable is coated with pressure-sensitive adhesive. A three-prong connector adapts the tape or cable to a utility outlet.

United States Patent 2,398,996 4/1946 Benander Inventors Howard PriceKings Point; Bela Szilagyi, Flushing, both of, N .Y. Appl. No. 753,229Filed Aug. 16, 1968 Patented June 15, 1971 Assignee InternationalPatents & Development Corporation ELECTRICAL TAPE AND PLUG CONNECTOR 6Claims, 4 Drawing Figs.

US. Cl. 339/14, 174/117, 339/196 Int. Cl H011 3/06 Field oiSearch339/12, 14, 17 F, 62,63, 195, 196, 22,23; 174/1 17, 115, 112,

References Cited UNITED STATES PATENTS 2,622,121 12/1952 Pedersen339/196 X 3,459,879 8/1969 Gerpheide 174/1 17 I FOREIGN PATENTS1,319,821 1/1963 France 174/ll7(.6)

684,915 12/1952 Great Britain 339/14 (P) Primary ExaminerMarvin A.Champion Assistant Examiner-Robert A. Hafer AtrorneySparrow and SparrowABSTRACT: An electrical tape and plug connector to facilitate simplifiedinstallation of electrical wiring. Substantially flat or film conductorsare sandwiched between insulating layers of protective material. Thesandwich includes a ground conductor insulated from the two main currentcarrying conductors. One surface of side of the tape or cable is coatedwith pressure-sensitive adhesive. A three-prong connector adapts thetape or cable to a utility outlet.

ELECTRICAL TAPE AND PLUG CONNECTOR BACKGROUND OF THE INVENTION In theinstallation of wiring for electrical systems, it is often desirable toinstall flat-shaped cable or wire tape. Such tape design permits thewiring to lie flatly against a wall surface, for example, and thus doesnot consume any substantial space nor alter the appearance of thesurface being wired. To provide protection from electrical shock, it isalso desirable to include within the tape, a ground conductor. Thisground conductor prevents electrical shock as aresult of defects whichmay prevail in the equipment to which the tape is connected, or indefects developed in the use of the tape itself. When using such flattape, or cable, at the same time, it is required that a suitable plugconnector be provided for the purpose of connecting the conductorswithin the tape to a utility outlet. The present invention provides anovel design of such a plug connector and thereby overcomes thedisadvantages that have prevailed heretofore, in the use of electricalconductor tapes.

SUMMARY OF THE INVENTION An electrical conductor tape or cable is formedby sandwiching two main current carrying conductors and a groundconductor between insulating layers of material. The ground conductor isarranged within the tape to assure that any electrical shock which maypossibly arise from defects within the tape, are prevented. The two mainconductors within the tape are maintained isolated from each otherthrough a novel design of the structure of the insulating layers. Thetape is used in conjunction with the plug connector which adapts thetape to use with a utility outlet. The plug connector includes twosections of a housing between which the tape or cable is maintained andsecurely connected to the prongs or pins of the connector. Setscrews ofinsulating material are threaded into the housing and cause the pressureplate to press the bared conductors of the cable firmly and intoelectrical contact with pins of the plug connector.

Various further and more specific purposes, features and advantages willclearly appear from the detailed description given below taken inconnection with the accompanying drawing which forms part of thisspecification and illustrates merely by way of example, embodiments ofthe device of the invention.

BRIEF DESCRIPTION OF THE DRAWING In the following description and in theclaims parts will be identified by specific names for convenience, butsuch names are intended to be as generic in their application to similarparts as the art will permit. Like reference characters denote likeparts in the several figures of the drawing, in which FIG. 1 is across-sectional view of the electrical tape or cable, and shows theconstruction in which the conductors of the tape or cable are maintainedelectrically isolated from each other;

FIG. 2 is a sectional side view of the plug connector for adapting thetape or cable of FIG. 1 to a utility outlet, in accordance with thepresent invention;

FIG. 3 is an end view taken along line 3-3 in FIG. 2 and shows thelayout of the connector pins;

FIG. 4 is a sectional view taken along line 4-4 in FIG. 2 and shows theinterconnection of the ground wire in the tape or cable with the groundpin of the plug connector.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawing and inparticular to FIG. 1. the electrical tape or conduit in accordance withthe present invention, has two current carrying conductors and 12sandwiched between two layers of insulating materials 14 and 16. Theinsulating layer 14 is provided with a pressure-sensitive coating 18.This pressure-sensitive coating in the form of an adhesive is applied tothe surface of the layer 14 which lies opposite to the surface incontact with the conductors 10 and 1.2. The pressure-sensitive adhesiveis provided on the external surface of the lay 14 for the purpose ofpermitting the tape or cable to be simply attached to a wall 20, forexample, shown in the drawing. The adhesive layer 18 permits theinstallation of the tape or cable with ease and without the use of anytools. Thus, no staples, cable clamps or other clips used conventionallyin the installation of conduits are required with the use of the tape inaccordance with the present invention.

The .two conductors l0 and 12 are maintained physically separated fromeach other through the space 22. By maintaining the two conductorsseparated in this manner, they are prevented from becoming shortenedthrough contact with each other. The layer 16, may further assure thatseparation between the two conductors l0 and 12 is maintained, bypartially filling the space 22 as shown in FIG. 1. Thus, as a result ofthe bend in the insulating layer 16, so that it extends into the space22, the conductors l0 and 12 are prevented from sliding into contactwith each other. The necessity for maintaining the two conductors 10 and12 separated from each other is well known in the art, in order toobtain a proper operating electrical circuit.

A ground conductor 26 is sandwiched between the insulating layer 16 and24. In use, the ground conductor is always maintained at groundpotential, regardless of the potential that may be applied to either theconductor 10 or 12. The ground conductor may be shaped to conform to thecontour of the insulating layer 16. Thus, the ground conductor 26 mayfollow the bend of insulating layer 16 which extends into the space 22.The inclusion of the ground conductor 26 serves as a protective means,as well known in the art, by preventing electrical shocks which mayresult from faulty equipment to which the tape or cable may beconnected. I-Ieretofore, however, such ground conductors within a cabledid not prevent electrical shocks from occurring as a result of defectsin the cable itself. Thus, in the usual cable available, in the past, itis possible to receive a shock when coming into contact with an area ofthe cable at which the insulation has worn off and one of the conductorsis exposed. Under such conditions, electrical shock can only beprevented if such exposed conductor were also connected to the groundconductor. This situation will, in general, not occur in the cablesdesigned as conventionally known. By bridging both conductors l0 and 12,in the manner shown in FIG. 1, the ground conductor 26 serves as afullproof safety device. Thus, by being spread over an area extendingthe full width of the cable, it is unlikely that any defect in theinsulation which may arise within the cable, will not cause theconductors l0 and 12 to short against the ground lead or conductor 26.Once such shorting action takes place between either one of theconductors I0 or 12 and the ground lead 26, any person in contact withthe cable will be protected from electrical shock. It is to be notedthat in a properly wired electrical system, adequate fuses will beincluded in the wiring, and these fuses will open the electrical circuitwhen such shorting action within the cable takes place due to defectsdeveloped therein.

The insulating layers l4, l6 and 24 may be constructed of Teflon, nylon,rubber, paper, or any suitable material having insulating or dielectricproperties. It is generally desirable that the conductors l0, l2 and 26be of copper or other good electrical conducting material, in order tomaintain any electrical losses through the cable at a low value. Theadhesive layer 18 may have a base of paper, or any substance having goodinsulating properties. The thickness of any one of the conductors may beof the order of 0.003 inches, whereas the thickness of an insulatinglayer may be within the range of 0.002 to 0.005 inches. The totalthickness of the tape may be within the range of 0.0l4 to 0.019 inches.

At both edges of the cable, directed longitudinally along the cableaxis, the insulating layers 14, 16 and 24 are pressed together andjoined through suitable adhesive or sealing substance. At the same time,these longitudinal sides of the cable may be sealed, in any conventionalmanner, such as through heat and pressure when the insulating layers aremade of, for example, plastics.

A plug connector 28 is provided for use with the cable 30, so that thelatter may be connected to a conventional utility outlet. The plugconnector 28 is provided with two prongs or connector pins 32 eachsecured to a base 34. The connector pins 32 and bases 34 are ofelectrically conducting material. The prongs or pins 32 together withtheir bases 34 are seated within the portion 36 of the housing of theplug connector 28. The design of the housing of the connector can besuch that the two sections of the housing are integrally constructed orconnected in two sections, such as 36 and 38 each being separate,attached together by conventional means such as a strap (not shown inthe drawing). A slot 40 is situated in the housing in order toaccommodate the tape or cable 30. The bared conductor 10 is brought intocontact directly with the conductive base 34 within the housing. In asimilar manner, the conductor 12 is brought into electrical contact withthe other conductive base 34. The insulating layers and adhesive layersurrounding the conductors are removed in the usual manner, preparatoryto inserting the end of the cable into the plug connector.

To maintain thelconductor 10 or 12 firmly in contact with base 34 ofprong or pin 32, a pressure plate or contact plate 42 is provided. Thispressure plate 42 is forced against the conductor 10 or 12 as a resultof the action of a screw 44. The section 38 of the housing is internallythreaded to accommodate the screw 44. Thus, when turning the screw intothe section 38, the screw is made to bear against the pressure plate 42and thisin turn, forces the conductor 10 or 12 in complete electricalcontact with the prong or pin 32 through the base 34. Furthermore,byproperly seating the screw 44 which may be in the form of a Setscrew,the cable 30 is prevented from slipping out of the plug connector. Thepressure plate 42 may be made of insulating material so that it maybridge the bases 34 of both pins or prongs 32 without shorting them.With such a design in which the pressure plate 42 is thus made ofinsulating material, only one setscrew 44 is required to maintain bothconductors l and 12 firmly against the bases 34, and hence in electricalcontact with the pins 32. It is quite feasible to also provide aseparate screw 44 for each one of the pins or prongs 32. In that event,the pressure plate 42 may be made of conductive material, providing thetwo pressure plates are maintained physically separated from each other.With this design,

at the same time, it is essential that the setscrew 44 be made of 45insulating material such as for example, nylon.

When assembling the cable 30 to the plug connector 28, the adhesivesurface of the cable faces the ground pin or prong 46 of the plugconnector. As a result, the ground conductor 26 is remotely locatedwithin the cable, from the pin 46. Thus, in the assembly, the pin 46 isadjacent to the conductor 10 and 12, whereas remotely located from theground conductor 26. In order to connect the ground pin 46 to the groundconductor 26 in the cable. or tape, the arrangement of FIG. 4 isprovided. The pin 46 is in electrical contact with a conducting plate 48which reaches around the edge of the tape and extends to the other sidethereof. The conducting plate 48 is firmly clamped to the groundconductor 26, through means of a setscrew 50. The latter is threadablyinserted into the section 38 of the housing of the plug connectorsimilarly to that described in relation to the setscrew 44. By drivingthe setscrew 50 into its proper seating position, the conducting plate48 is pressed against the bare conductor 26, and thus electricalcontinuity is established'between the ground conductor 26 and the pin46. The setscrew 50 is made of insulating material such as nylon,similar to that of setscrew 44. Furthermore, the housing of the plugconnector is also made of insulating material to prevent interaction ofthe prongs or pins 32 and the pin 46. Materials such a plastic or rubberare suitable for this purpose.

While the invention has been described and illustrated with respect to acertain preferred example which gives satisfactory results, it will beunderstood by those skilled in the art after understanding the rincipleof the invention, that various changes and mod! lcations may be madewithout departing from the spirit and scope of the invention and it isintended therefore in the appended claims to cover all such changes andmodifications.

What we claim is: I

1. Electrical tape and connector combination comprising:

a. two conductors disposed longitudinally parallel to each other andelectrically isolated from each other for carrying current in a closedcircuit, said two conductors having a rectangular cross section in whichthe thickness is substantially smaller than the width;

b. a ground conductor straddling said two conductors and electricallyisolated therefrom, said ground conductor being disposed adjacent saidtwo conductors and having a rectangular cross section in which thethickness is substantially smaller than the width, the width of saidground conductor straddling the combined widths of said two conductors;

. electrically insulating strip means between said two conductors andsaid ground conductor to retain said conductors isolated from eachother;

d. adhesive strip means secured to an exterior side of one of saidinsulating strips for mounting said tape on a desired surface, thecombination of said conductors, insulating strip means and adhesivestrip means comprising a three conductor tape cable;

e. connector prongs in contact with the ends of said two conductors;

f. a ground connector prong in contact with the end of said groundconductor;

g. a connector housing with a slot for receiving said tape cable andwith a cavity communicating with said slot for holding said two prongs,said two prongs projecting partially from said housing through openingsthereof, said housing having a recess for holding said ground connectorprong; clamping means within said slot and said cavity and in contactwith said conductors for clamping said conductors to said prongs so thatsaid conductors are in electrical contact with said prongs; firstthreaded fastening means threaded in said housing and in contact withsaid clamping means for forcing said clamping means against said twoconductors and said two prongs; a U- shaped conductive member in contactwith said ground prong and with said ground conductor; and secondthreaded fastening means threaded in said housing and in contact withsaid clamping means for forcing said clamping means against said groundconductor and said ground prong.

2. The electrical tape and connector combination as defined in claim 1wherein said electrically insulating strips are of Teflon" material.

3. The electrical tape and connector combination as defined in claim 2wherein said insulating strips are sealingly joined to each other attheir edges along the longitudinal axis of said tape.

4. The electrical tape and connector combination as defined in claim 1wherein said conductors are disposed between said ground conductor andsaid adhesive strip.

5. The electrical tape and connector combination as defined in claim 1wherein said adhesive strip is pressure-sensitive for securing said tapefirmly against said surface through application of substantially lightpressure.

6. The electrical tape and connector combination as defined in claim 1wherein said threaded fastening means comprises a fastening screw ofinsulating material threadably received by said housing.

1. Electrical tape and connector combination comprising: a. twoconductors disposed longitudinally parallel to each other andelectrically isolated from each other for carrying current in a closedcircuit, said two conductors having a rectangular cross section in whichthe thickness is substantially smaller than the width; b. a groundconductor straddling said two conductors and electrically isolatedtherefrom, said ground conductor being disposed adjacent said twoconductors and having a rectangular cross section in which the thicknessis substantially smaller than the width, the width of said groundconductor straddling the combined widths of said two conductors; c.electrically insulating strip means between said two conductors and saidground conductor to retain said conductors isolated from each other; d.adhesive strip means secured to an exterior side of one of saidinsulating strips for mounting said tape on a desired surface, thecombination of said conductors, insulating strip means and adhesivestrip means comprising a three conductor tape cable; e. connector prongsin contact with the ends of said two conductors; f. a ground connectorprong in contact with the end of said ground conductor; g. a connectorhousing with a slot for receiving said tape cable and with a cavitycommunicating with said slot for holding said two prongs, said twoprongs projecting partially from said housing through openings thereof,said housing having a recess for holding said ground connector prong;clamping means within said slot and said cavity and in contact with saidconductors for clamping said conductors to said prongs so that saidconductors are in electrical contact with said prongs; first threadedfastening means threaded in said housing and in contact with saidclamping means for forcing said clamping means against said twoconductors and said two prongs; a Ushaped conductive member in contactwith said ground prong and with said ground conductor; and secondthreaded fastening means threaded in said housing and in contact withsaid clamping means for forcing said clamping means against said groundconductor and said ground prong.
 2. The electrical tape and connectorcombination as defined in claim 1 wherein said electrically insulatingstrips are of ''''Teflon'''' material.
 3. The electrical tape andconnector combination as defined in claim 2 wherein said insulatingstrips are sealingly joined to each other at their edges along thelongitudinal axis of said tape.
 4. The electrical tape and connectorcombination as defined in claim 1 wherein said conductors are disposedbetween said ground conductor and said adhesive strip.
 5. The electricaltape and connector combination as defined in claim 1 wherein saidadhesive strip is pressure-sensitive for securing said tape firmlyagainst said surface through application of substantially lightpressure.
 6. The electrical tape and connector combination as defined inclaim 1 wherein said threaded fastening means comprises a fasteningscrew of insulating material threadably received by said housing.